Preparation of non-spun silk and corresponding products

ABSTRACT

A method for preparing a textile can include obtaining silk components, such as non-spun silk components, from a cocoon. The method can also involve assembling the obtained silk components obtained from the cocoon into a pattern, and attaching the non-spun silk components together. The method can still further involve shaping the attached non-spun silk components, and finalizing the shape through heat-treatment. In one implementation, heat-treatment of the shaped components comprises heating the components with a heating apparatus (e.g., iron, or oven, etc.) for an appropriate time and at an appropriate temperature. A variety of end products, including jewelry, and textiles for further processing generally, can be made from the silk prepared in accordance with an implementation of the invention.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of prior U.S. ProvisionalApplication No. 61/348,629 filed on May 26, 2010, which is incorporatedby reference in its entirety.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention relates generally to the production of natural fibertextiles, including those made from naturally-occurring materials suchas silk cocoons.

2. Background and Relevant Art

Silk is a natural fiber, made of protein, and produced by insects andspiders. For example, the earliest silk was thread obtained from thesilk moth Antheraea, and in particular Antheraea mylitta. More recently,workers obtain silk from silkworm species, such as the domesticatedsilkworm, Bombyx mori (B. mori), or the wild silkworm Boroceramadagascariensis (B. madagascariensis).

In the case of the domesticated silkworm, B. mori, a worker can obtainsilk thread by unwinding a cocoon. (The process of unwinding the silkfilaments from the cocoon and combining them together to make a threadof raw silk can be termed “reeling.”) In other cases, such as silkwormspecies like B. madagascariensis, the silk thread cannot be reeled orunwound, and so a worker may boil the cocoon until it breaks down intoits component fiber. After boiling, the worker can spin the silk fibermuch like wool, cotton, flax, linen or other fibers that can be bundledinto a yarn. Either reeled/unwound silk or spun silk can be transformedinto area-covering textiles using warp-weft weaving.

Unfortunately, silk production can require a substantial farmerfinancial investment by the farmer in both silkworm seed stock, inlarval food plants, and silkworm and plant rearing and growingtechnology. Similarly, silk thread and textile production can require asubstantial, additional investment in spinning and weaving equipment.The initial investment required for silk production, especially with thedomesticated silkworm, can make it inaccessible to subsistence farmerswithout significant, additional, financial resources.

BRIEF SUMMARY OF THE INVENTION

A new type of non-spun, silk textile can be made with indigenous speciesof silkworms that feed on indigenous plants. The textile can provide alow-cost alternative to traditional silk production. Instead ofdecomposing the cocoons into fibers that can be spun or reeled, thecocoons can be used “as is” and assembled into an area-covering fabric.Because the method uses only indigenous plant and animal species, themethod may not adversely affect ecologically sensitive sites, and mayassist in benefiting ecologically sensitive sites by promotingre-establishment of the native food plants of the indigenous silk moths.At least one embodiment relates to heat treatment used to flatten thecocoons prior to textile production, during assembly, and to constructthe textile into three-dimensional forms.

In one aspect, a textile can include a non-spun silk component. Anon-spun silk component can include silk fibers obtained from a silksource. A silk source can be a cocoon, more specifically, a singlecocoon. A cocoon can be a silkworm cocoon. The silk fibers may not bereeled, unwound or spun.

In some embodiments, a non-spun silk component can consist essentiallyof silk fibers obtained from a single cocoon or silk fibers obtainedfrom a single layer of a cocoon. In other words, a non-spun silkcomponent can be free of a glue, a polymer, a plastic or other binder.

In some embodiments, a textile can include a plurality of non-spun silkcomponents. A plurality can be any number greater than one, for example,a plurality can be greater than 10, greater than 25, greater than 50,greater than 100, greater than 200, greater than 300, greater than 400or greater than 500. In some embodiments, each non-spun silk componentcan consist essentially of silk fibers obtained from a single cocoon orsilk fibers obtained from a single layer of a cocoon. Each non-spun silkcomponent can be free of a glue, a polymer, a plastic or other binder.

In some embodiments, a cocoon can include a plurality of layers. In apreferred embodiment, a cocoon can include an inner layer and an outerlayer. In some embodiments, a non-spun silk component can include aninner layer and/or an outer layer.

In some embodiments, a textile can further include one or more threads.In some embodiments, one or more threads can attach a first non-spunsilk component to a second non-spun silk component. In some embodiments,one or more threads can attach a first subset of non-spun silkcomponents to a second subset of non-spun silk components, where asubset can include one or more non-spun silk components.

In some embodiments, a textile can further include one or moreattachment devices. In some embodiments, one or more attachment devicescan attach a first non-spun silk component to a second non-spun silkcomponent. In some embodiments, one or more attachment devices canattach a first subset of non-spun silk components to a second subset ofnon-spun silk components, where a subset can include one or morenon-spun silk components. An attachment device can include an adhesive,a clasp, a button, a VELCRO™, a snap, or a zipper.

In some embodiments, a textile can include a shaped non-spun silkcomponent, wherein the shaped non-spun silk component has beenmanipulated to obtain its shape. In some embodiments, a component can bemanipulated by flattening, cutting, folding or texturizing.

In some embodiments, a non-spun silk component can include sericin. Insome embodiments, the sericin has been redistributed, for example by,heating the sericin.

In another aspect, a method of preparing a textile can include obtainingone or more non-spun silk components from a silk source. A non-silkcomponent can include silk fibers obtained from a silk source. A silksource can be a cocoon. A cocoon can be a silk worm cocoon. The silkfibers may not be reeled, unwound or spun.

In some embodiments, a non-spun silk component can consist essentiallyof silk fibers obtained from a single cocoon or silk fibers obtainedfrom a single layer of a cocoon. In other words, a non-spun silkcomponent can be free of a glue, a polymer, a plastic or other binder.

In some embodiments, a cocoon can include a plurality of layers. In someembodiments, a cocoon can include an inner layer and an outer layer. Insome embodiments, a non-spun silk component can include an inner layerand/or an outer layer.

In some embodiments, obtaining the one or more silk components caninclude removing a live, insect pupa and chrysalis from a cocoon. Insome embodiments, obtaining one or more silk components can includewashing the cocoon, for example, in soap and water. In some embodiments,obtaining one or more silk components can include drying the cocoon. Acocoon can be dried by air drying or drying the cocoon with theassistance of heat. Drying the cocoon with the assistance of heat can beperformed with an oven, an iron or a blow dryer, for example. Drying thecocoon with the assistance of heat can also be performed by placing thecocoon in a location which receives sunshine.

In some embodiments, a method can further include assembling the one ormore non-spun silk components.

In some embodiments, one or more non-spun silk components can beassembled from the cocoon without reeling, unwinding, or spinning.

In some embodiments, the one or more non-spun silk components can beassembled from the cocoon without reeling, unwinding, or spinning. Insome embodiments, assembling the non-spun silk components can includeselecting non-spun silk components based on color, quality or size. Insome embodiments, assembling the non-spun silk components can includemanipulating a non-spun silk component. A non-spun silk component can bemanipulated by, for example, flattening, cutting, folding, tinting,dyeing or texturizing. In some embodiments, assembling the non-spun silkcomponents can include positioning the one or more non-spun silkcomponents into a pattern. In some embodiments, assembling the non-spunsilk components can include attaching or sewing the one or more non-spunsilk components together.

In some embodiments, assembling the non-spun silk components can includeheat treating a non-spun silk component. For example, a non-spun silkcomponent can be ironed.

In some embodiments, a method can further include ironing the cocoon asa double layer. In some embodiments, a method can further includeseparating the two layers of the cocoon into two independent componentsand ironing the separated independent components.

In some embodiments, a method can include finalizing the one or morenon-spun silk components. Finalizing the one or more non-spun silkcomponents can include finalizing the one or more non-spun silkcomponents into a shape.

In some embodiments, finalizing the assembled non-spun silk componentscan include forming the assembled non-spun silk components into theshape.

In some embodiments, finalizing the assembled non-spun silk componentscan further include heat treating the shaped non-spun silk components.

In some embodiments, heating the shaped non-spun silk components by useof a heating apparatus can include heating a heating apparatus and/ornon-spun silk component to between about 200° F. to about 500° F.,preferably about 350° F. In some embodiments, heating the shapednon-spun silk components by use of a heating apparatus can includemaintaining the assembled non-spun silk components in or in contact withthe heated heating apparatus for between about 2 minutes to about 20minutes, preferably about 8 minutes.

In some embodiments, a method can include heat treating. Obtaining oneor more non-spun silk components from a silk source, assembling the oneor more non-spun silk components and/or finalizing the one or morenon-spun silk components can include heat treating.

In some embodiments, heat-treating the shaped components can includeheating the one or more shaped non-spun silk components using a heatingapparatus. Heat treating can include heating a heating apparatus and/ora non-spun silk component to a temperature greater than 150° F., greaterthan 200° F., greater than 250° F., greater than 300° F., greater than350° F., greater than 400° F. or greater than 450° F. A heat treatmentcan last for at least 2 minutes, at least 5 minutes, at least 10minutes, at least 15 minutes, at least 20 minutes or at least 30minutes. A heat treatment can last for at most 1 hour, at most 45minutes, at most 30 minutes, at most 15 minutes, or at most 10 minutes.In a preferred embodiment, a heat treatment can last between 2 and 20minutes, even more preferable, between 5 and 15 minutes.

One will appreciate that such apparatus can comprise virtually anyappropriate heating apparatus such, including but not limited to aconvection or conventional heating apparatus (or even a microwaveheating apparatus) including a conventional oven, a convection oven, aniron or a microwave oven. A heating apparatus can include vacuum ovensand autoclaves. Heating can include using fire, steam, electricity orirradiation.

In some embodiments, using a heating apparatus can include one or moreof heating the shaped non-spun silk components with an iron, or heatingthe shaped non-spun silk components by use of an oven.

Additional features and advantages of exemplary implementations of theinvention will be set forth in the description which follows, and inpart will be understood from the description, or may be learned by thepractice of such exemplary implementations. The features and advantagesof such implementations may be realized and obtained by means of theinstruments and combinations particularly pointed out in the appendedclaims. These and other features will become more fully apparent fromthe following description and appended claims, or may be learned by thepractice of such exemplary implementations as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otheradvantages and features of the invention can be obtained, a moreparticular description of the invention briefly described above will berendered by reference to specific embodiments thereof, which areillustrated in the appended drawings. Understanding that these drawingsdepict only typical embodiments of the invention and are not thereforeto be considered to be limiting of its scope, the invention will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings in which:

FIG. 1 is a photograph illustrating a cocoon recently spun by a silkwormA. suraka, with caterpillar visible inside;

FIG. 2 is a photograph illustrating a top view of an inner layer of acocoon (such as shown in FIG. 1), in which an inner layer has beenseparated from an outer layer;

FIG. 3 is a photographic depiction of a production team as the memberscut and pin cocoons to a patter, and as they sew cocoon components intextile assembly;

FIG. 4 is a photograph illustrating a textile, such as after theproduction shown in FIG. 3;

FIG. 5 is a photographic depiction of pendant made from heat-treatedwild silk;

FIG. 6 is a photograph illustrating a close-up view of a non-spun,needled textile assembled from silk cocoons;

FIG. 7 is another photograph illustrating a close-up view of a non-spun,needled textile assembled from silk cocoons; and

FIGS. 8 through 10 are photographs illustrating various sequences in oneimplementation of a disclosed method.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In one aspect, a textile can be a natural textile, for example, silk. Atextile may not be or include paper. A textile can be free from a glue,a polymer or other binder. A textile can consist essentially of silk. Asilk or silk textile can include non-spun silk. A silk can be made bysilkworms.

In an exemplary embodiment, a silk textile can be made with a species ofsilkworm indigenous (i.e. native or grown in the region where thetextile is made). Preferably, an indigenous silkworm can be fed onindigenous plants (i.e. plants which can be native or can be grown inthe region where the silkworm is raised and/or where the textile ismade). The textile can provide a low-cost alternative to textileproduction, for example, when compared to traditional silk production.Instead of decomposing the cocoons into fibers that are spun or reeled,cocoons can be used “as is” and can be assembled into a textile or anarea-covering fabric. Decomposing the cocoons into fibers can includeremoving a fiber from the cocoon to be used as a single fiber or thread.This can be performed by unraveling a fiber from a cocoon. Because themethod can use only indigenous plant and animal species, the method maynot adversely affect ecologically sensitive sites, and may assist inbenefiting an ecologically sensitive site by promoting re-establishmentof the native food plants of the indigenous insects, for example, silkworms or silk moths. A method can include heat treatments. Heattreatments can be used to flatten the cocoons prior to textileproduction, during assembly, and/or to construct the textile intothree-dimensional forms.

For example, assembling flattened, silk cocoons into an area-coveringtextile or sheet can make a non-spun fabric. A non-spun silk componentcreated can be a textile or can be assembled into a textile includingmultiple non-spun silk components. This method of constructing a silktextile/fabric can have an added advantage of avoiding the substantialequipment and training costs that can be needed to make spun silk andwoven textiles. This method can also take advantage of the fact thatcocoons that can be used (e.g. silk cocoons spun by the silk moths inthe family Saturniidae) can be coated with a heavy layer of sericin orprotein glue that can make the thread difficult to spin and can make thethread almost impossible to reel. Nevertheless, when the cocoon isheated (including by oven-heating or ironing), the sericin can softensand can spread over the fibers to flatten and stiffen them. Uponcooling, the flattened cocoon can be easy to sew into fabric or forminto a three-dimensional shape.

Silk Preparation

A non-spun silk component can be obtained from a silk source, forexample, a cocoon, more specifically, a silkworm cocoon. The silk fibersmay not be reeled, unwound or spun.

Obtaining a non-spun silk component can include silk preparation. A silkpreparation process can start by removing the live, insect pupa or thechrysalis from the cocoon, exemplified by FIG. 1. The insect pupaeand/or chrysalis can be removed from a cocoon by a number of methods,including, but not limited to, physical extraction (e.g. cutting thepupa and chrysalis from the cocoon). In the alternate, an insect pupaeand/or chrysalis can be removed from a cocoon by other physicalextraction methods (e.g. crushing the pupa and chrysalis, heatliquefying the pupa and chrysalis) or chemical extraction (e.g.dissolving the pupa and chrysalis in a chemical). The cocoon can then bewashed. Washing can include any process for cleaning the cocoon, forexample, washing the cocoon in water or washing the cocoon in soap andwater. The cocoon can also be dried. Drying can include air drying, blowdrying or drying with heat.

A cocoon can be of a variety of colors, properties (e.g. fiberproperties) or qualities. For example, a cocoon can be darker orlighter. A cocoon can include a thick fiber or a thin fiber. The fiberof a cocoon may have a sheen or a gloss. Some cocoons can have fiberthat can have a more consistent fiber texture, fiber size, or color. Insome embodiments, a cocoon can be selected based on a color, property orquality of a cocoon.

Cocoon Preparation and Assembly

A method can include a heat treatment. Heat treatments can be a criticalcomponent of textile preparation. A heat treatment can be performedduring multiple steps, for instance, during the preparation step (e.g.during washing or drying of a cocoon), after drying a cocoon, during themanipulation of a non-spun silk component, or after the manipulation ofa non-spun silk component. Heat treatment can include heating to atemperature greater than 150° F., greater than 200° F., greater than250° F., greater than 300° F., greater than 350° F., greater than 400°F. or greater than 450° F. A heat treatment can last for at least 2minutes, at least 5 minutes, at least 10 minutes, at least 15 minutes,at least 20 minutes or at least 30 minutes. A heat treatment can lastfor at most 1 hour, at most 45 minutes, at most 30 minutes, at most 15minutes, or at most 10 minutes. In a preferred embodiment, a heattreatment lasts between 2 and 20 minutes, even more preferable, between5 and 15 minutes.

One will appreciate that such apparatus can comprise virtually anyappropriate heat such, including but not limited to a convection orconventional heating apparatus (or even a microwave heating apparatus)including a conventional oven, a convection oven, an iron or a microwaveoven. A heating apparatus can include vacuum ovens and autoclaves.Heating can include using fire, steam, electricity or irradiation.

For example, after drying, the cocoon can be heat-treated as part ofassembling the non-spun silk components. The cocoon can be heat treatedas a particular layer, such as ironed as a double layer. Alternatively,the layers of the cocoon can be separated into independent componentsand heat treated (e.g. ironed), such as shown in FIG. 2. A cocoon canhave a plurality of layers. In other words, the cocoon can have morethan one layer, for example, two, three, four or more layers. In apreferred embodiment, the cocoon can have two layers, an inner layer andan outer layer. In some embodiments, for example, a worker can ironcocoon as a double layer or a single layer component.

Heat treatments can be used to soften sericin or protein glue of acocoon or to change a quality or property of a silk fiber (e.g. softenor stiffen a silk fiber).

A worker can assemble the non-spun silk components. A non-spun silkcomponent can be a textile. A non-spun silk component can be a cocoonthat has been prepared. A heat treatment can include flattening orotherwise shaping a cocoon. A worker can attach or sew the component tomake a textile or a textile including multiple non-spun silk components.(For example, FIG. 3 illustrates a team performing various assembliesfrom the double or single layer components.)

The non-spun silk components can also be manipulated. For example, anon-spun silk component can be cut, shaped, tinted, dyed, folded ortexturized. In some embodiments, a non-spun silk component can be cutinto different shapes and/or sizes. A non-spun silk component can bepinned into a pre-designed pattern. This modular approach to fabricassembly and production can allow textiles of any size to be made (e.g.,FIG. 4). It can also allow the textile to be easily transported, forexample, from remote areas to market centers.

After a fabric or textile has been produced, the fabric or textile canbe heat-treated (e.g., ironed and/or oven-heated) to stiffen it onceagain. If the textile has been formed into a three-dimensional shape, itcan be placed in a heating apparatus of sufficient temperature and forsufficient duration.

For example, in one implementation, the heating apparatus temperaturecan be between about 200° F. and about 500° F., preferably between about300° F. to about 400° F. Similarly, the worker can heat the shapedtextile in the heating apparatus from about 2 minutes to about 20minutes, preferably from about 5 minutes to about 15 minutes. In atleast one implementation, the worker can heat the shaped silk textile ina heating apparatus that has been heated to about 350° F. for about 8minutes. After cooling, the textile shape can be retained essentiallypermanently. Along these lines, FIG. 5 is a photograph illustrating ashaped silk textile that has undergone this additional heating andcooling sequence.

Thread And Stitching

In at least one implementation, the type of thread used to sew thenon-spun silk components into a fabric or textile can be critical to thefinal design of the fabric. Where it is desired that the thread not beseen, the fabric can be sewn with transparent or “invisible” thread, forexample, 100%, polyester and made by SULKY. The thread can be tinted orun-tinted depending on the cocoon color and desired effect. For example,FIG. 6 illustrates a textile made using a translucent/transparent, smokythread. Of course, one will appreciate that the stitching can be done aspart of the macro-pattern of the textile, and a variety of threads andembroidery techniques can be used thereby. In these cases, the threadmay be selected to contrast with the cocoon and may be chosen from anytype of fiber whether synthetic, natural or mixed synthetic natural.

FIG. 6 illustrates a textile made using a zig-zag pattern. In oneimplementation, the illustrated zig-zag stitch can mimic the irregular,fractal-like spinning of the silk moth. One will appreciate that thezig-zag stitch can be sewn by hand or machine. Hence, the micro-designof the resulting fabric can be simply as it appears in nature, butinstead of a 2 inch silk fragment (or cocoon) the textile can beextended to any desired size. Furthermore, one will appreciate that theresulting textile can be light-weight, and can be easily shipped inmodules.

Additionally or alternatively, individual cocoon components may also becut into shapes that are laid in either geometric designs, ornon-geometric patterns. For example, FIG. 7 is a photograph illustratinga sequence of standard square or rectangle patterns. Regardless of thetextile pattern, the preferred stitching can include a zig-zag stitch,such as exemplified in FIGS. 6 and 7. Other stitch styles or patternsother than zig-zag can be appropriate in some cases, and such stitchingcan affect not only style but strength of the end product. Inparticular, there will be some cases where the stitching forms part ofthe design, whereas, in other cases, the stitching will not form part ofthe design, but will provide primarily attachment support betweennon-spun silk components or components. Furthermore, other attachmentmeans may be useful in some cases beyond stitching or sewing, includingattachment methods for example, adhesives (e.g. glues), VELCRO™, snaps,buttons or tapes. It is important to differentiate an adhesive or binderas a means of attaching components from an adhesive or binder used toform a non-spun silk component. An adhesive or binder as an attachmentmeans can be present only on a portion of a non-spun silk component forthe purpose of attaching one non-spun silk component to another. Anadhesive or binder used to form a non-spun silk component can be presentthroughout the entirety of a single non-spun silk component for thepurpose of creating or stabilizing the non-spun silk component.

Once the worker has completed assembling and attaching the raw non-spunsilk components, the worker can then finalize the textile. In at leastone implementation, this finalization can involve heating treating thesewn/attached components. The finalization can, for example, includeironing. The finalization can include ironing and another form of heattreatment. The result can be an aesthetically pleasing textilecomprising non-spun silk. The non-spun silk can be light-weight andeasily usable in a wide range applications, including jewelry andtextiles

The textile can be free of dye and/or tint. Alternatively, the textilecan be dyed or tinted.

FIGS. 8 through 10 are photographs illustrating various sequences in oneimplementation of the inventive production process. For example, FIGS.8, 9 and 12 illustrate positioning sewn non-spun silk components on apattern −/− grid. FIGS. 10 and 11 show workers sewing various non-spunsilk components that have previously been extracted and cut fromcocoons. FIG. 13 shows a large section of nearly finalized textile thathas been assembled and shown in a pattern corresponding to the papergrid shown underneath. FIG. 14 is a photograph showing a worker sewingextracted and cut non-spun silk components.

In describing some embodiments, the term “worker”, “member”, “team” or“team member” has been used to refer to a person. However, it should beunderstood that a “worker”, “member”, “team” or “team member” can alsobe a machine or automated device, such that a method or a step of amethod can be performed or completed by an automated device or machine.As a non-limiting example, a worker performing a step of sewing silktextile should also be understood to encompass a machine or automateddevice performing a step of sewing a silk textile.

EXAMPLES Example 1

In a series of experiments, cocoons were assembled into two-dimensionaltextiles. The silk textile can be unique because it is not woven fromspun fibers. Instead, the cocoons were treated, assembled and sewn tomake a fabric. The preparation process involved removing the insectpupae before emergence, cleaning the cocoon and separating it into itstwo component layers. The silk was then heat-treated (ironed). Thecocoons were used in either their natural form or cut into geometricshapes, such as squares, rectangles and circles. The shapes were sewntogether with different types of threads. In the first case, cottonthread whose color matched the cocoons was used. The textile was sewn byhand using a zigzag stitch.

Example 2

In a second series of experiments, the cocoons were stitched togetherusing 100% polyester, “invisible” thread purchased from Speed Stitch,S.C. Both clear “invisible thread” as well as smoke-tinted, “invisiblethread” was used. The cocoons were stitched together using a zigzagstitch by hand or machine. The result was a textile that does not appearto be sewn but the silk pieces appear to be fused. Textiles were madeusing the natural shape of the cocoon, as well as geometric shapes.

The invention may be embodied in other specific forms without departingfrom its spirit or essential characteristics. The described embodimentsare to be considered in all respects only as illustrative and notrestrictive. The scope of the invention is, therefore, indicated also bythe appended claims rather than by the foregoing description alone.

1. A textile, the textile comprising a non-spun silk component.
 2. Thetextile of claim 1, wherein a non-spun silk component consistsessentially of silk fibers obtained from a single cocoon.
 3. The textileof claim 1, wherein the textile comprises a plurality of non-spun silkcomponents.
 4. The textile of claim 2, wherein each non-spun silkcomponent consists essentially of silk fibers obtained from a singlecocoon.
 5. The textile of claim 3, further comprising one or morethreads.
 6. A method of preparing a textile comprising: obtaining one ormore non-spun silk components from a silk source; assembling the one ormore non-spun silk components; and finalizing the one or more non-spunsilk components into a shape.
 7. The method as recited in claim 6,wherein: the silk source is a cocoon; and the one or more non-spun silkcomponents are assembled from the cocoon without reeling, unwinding, orspinning.
 8. The method as recited in claim 6, wherein assembling thenon-spun silk components comprises: positioning the one or more non-spunsilk components into a pattern; and attaching or sewing the one or morenon-spun silk components together.
 9. The method as recited in claim 6,wherein finalizing the assembled non-spun silk components comprises:forming the assembled non-spun silk components into the shape.
 10. Themethod as recited in claim 9, wherein finalizing the assembled non-spunsilk components further comprises heat treating the shaped the shapedcomponents.
 11. The method as recited in claim 10, wherein heat-treatingthe shaped components comprises heating the one or more shaped non-spunsilk components using a heating apparatus.
 12. The method as recited inclaim 11, wherein using a heating apparatus includes one or more of:heating the shaped non-spun silk components with an iron; or heating theshaped non-spun silk components by use of an oven.
 13. The method asrecited in claim 11, wherein heating the shaped non-spun silk componentsby use of a heating apparatus comprises: heating the heating apparatusto between about 200° F. to about 500° F., preferably about 350° F.;maintaining the assembled non-spun silk components in the heated heatingapparatus for between about 2 minutes to about 20 minutes, preferablyabout 8 minutes.
 14. The method as recited in claim 6, wherein obtainingthe one or more non-spun silk components comprises: removing a live,insect pupae and chrysalis from a cocoon; washing the cocoon in soap andwater; and drying the cocoon.
 15. The method as recited in claim 14,further comprising: ironing the cocoon as a double layer; or separatingthe two layers of the cocoon into two independent components and ironingthe separated independent components.